Deckle technology

Abstract

The invention provides a deckle system for extrusion dies. In certain embodiments, the invention provides methods of cleaning an extrusion die equipped with a retractable external deckle system. Also provided in some embodiments is a deckle system having a novel deckle adjustment mechanism. In other embodiments, the invention provides an advantageous internal deckle member equipped with a removable, replaceable internally threaded insert.

What is claimed is: 
     
       1. An extrusion die having a deckle system, manifold, a preland channel, a final land channel, and an orifice, said preland channel having a downstream end region, said final land channel having an upstream end region, a transition zone extends from said downstream end region of said preland channel to said upstream end region of said final land channel, said deckle system including an end plate mounted to said extrusion die and an external deckle having a retractable base, said retractable base mounted so as to be moveable transversely away from said orifice to expose a cleaning access defined by said deckle system, without having to disassemble said deckle system or said extrusion die, said cleaning access configured to receive a scraper for cleaning unwanted material from said transition zone, said cleaning access being spaced transversely away from said extrusion die and located transversely away from said end plate of said deckle system. 
     
     
       2. The extrusion die of  claim 1  wherein said retractable base has a first end region adjacent to said extrusion die, and wherein, when said cleaning access is exposed by moving said retractable base transversely away from said orifice, said cleaning access is bounded by said first end region of said retractable base. 
     
     
       3. The extrusion die of  claim 1  wherein said end plate has a slot opening passing transversely through said end plate, and wherein, when said retractable base is moved transversely away from said orifice to expose said cleaning access, said slot opening passing transversely through said end plate opens to said cleaning access, such that an access path for the scraper extends first through said cleaning access, then transversely along said slot opening, and into said transition zone and said final land channel. 
     
     
       4. The extrusion die of  claim 3  wherein said slot opening passing transversely through said end plate opens to, and extends between, said cleaning access on one side and said transition zone and said final land channel on another side. 
     
     
       5. The extrusion die of  claim 1  wherein said retractable base has a concave generally boat-shaped configuration having an end region with two projection bars that are at least generally parallel to each other and to said orifice. 
     
     
       6. The extrusion die of  claim 5  further comprising an end, said end plate mounted to said end, said end plate has two openings, each of said two projection bars of said retractable base are received by a respective one of said openings. 
     
     
       7. The extrusion die of  claim 1  wherein said deckle system includes an internal deckle member that is adjustable transversely and a movable carrier, said internal deckle member being mounted to said movable carrier such that in response to transverse movement of said movable carrier said internal deckle member is adjusted transversely. 
     
     
       8. The extrusion die of  claim 5  wherein said deckle system includes an internal deckle member that is adjustable transversely and a movable carrier, said internal deckle member being mounted to said movable carrier such that in response to transverse movement of said movable carrier said internal deckle member is adjusted transversely, said retractable base being mounted to said movable carrier. 
     
     
       9. The extrusion die of  claim 1  wherein said deckle system includes an internal deckle rod, a deckle quill, and a secondary deckle flag, said internal deckle rod configured to move transversely out of said transition zone in response to movement of said retractable base, said deckle quill disposed in said manifold, and said secondary deckle flag disposed in said preland channel. 
     
     
       10. A deckle system having an external deckle and an end plate, said end plate having a die side and a distal side, said die side configured to be mounted on an end of an extrusion die, said end plate having a slot opening passing transversely through said end plate, said external deckle having a retractable base, said retractable base mounted so as to be moveable transversely away from said end plate to expose a cleaning access defined by said deckle system, without having to disassemble said deckle system, said cleaning access configured to receive a scraper, said cleaning access located transversely away from, and outwardly of, said end plate, such that said cleaning access is on said distal side of said end plate and is external to the extrusion die when said end plate is mounted to the extrusion die, and said slot opening passing transversely through said end plate opens to said cleaning access, such that an access path for the scraper extends first through said cleaning access and then transversely along said slot opening. 
     
     
       11. The deckle system of  claim 10  wherein said retractable base has a first end region, and wherein, when said cleaning access is exposed by moving said retractable base transversely away from said end plate, said cleaning access is located between said end plate and said first end region of said retractable base. 
     
     
       12. The deckle system of  claim 11  wherein said retractable base has two projection bars that project from said first end region of said retractable base, said two projection bars are at least generally parallel to each other, and wherein, when said cleaning access is exposed by moving said retractable base transversely away from said end plate, said two projection bars bound said cleaning access. 
     
     
       13. The deckle system of  claim 12  wherein said end plate has two openings, each of said two projection bars of said retractable base are received by a respective one of said openings. 
     
     
       14. The deckle system of  claim 10  further comprising an internal deckle member that is adjustable transversely, and a movable carrier, said internal deckle member being mounted to said movable carrier such that in response to transverse movement of said movable carrier said internal deckle member is adjusted transversely, said retractable base being mounted to said movable carrier. 
     
     
       15. The deckle system of  claim 14  wherein said internal deckle member comprises a quill, said deckle system further comprising a secondary flag and an internal deckle rod, said quill being mounted to said movable carrier, said secondary flag being mounted to said movable carrier, and said internal deckle rod being mounted to said retractable base. 
     
     
       16. The extrusion die of  claim 1  wherein said deckle system includes a movable carrier comprising a body, a plurality of transverse openings extend through said body, and a plurality of beams mounted respectively in said transverse openings, such that said carrier is movable transversely along said beams. 
     
     
       17. The extrusion die of  claim 16  wherein said deckle system includes a drive system configured to move said carrier transversely. 
     
     
       18. The extrusion die of  claim 3  wherein said access path extends in an upstream direction through said cleaning access, then transversely along said slot opening, and into said transition zone and said final land channel. 
     
     
       19. The extrusion die of  claim 7  wherein said retractable base has a first configuration in which said retractable base is locked to said movable carrier and a second configuration in which said retractable base is free to move transversely relative to said movable carrier. 
     
     
       20. The deckle system of  claim 10  further comprising a movable carrier having a body, a plurality of transverse openings extend through said body, and a plurality of beams mounted respectively in said transverse openings, such that said carrier is movable transversely along said beams. 
     
     
       21. The deckle system of  claim 20  further comprising a drive system configured to move said deckle carrier transversely. 
     
     
       22. The deckle system of  claim 10  wherein when said retractable base is moved transversely away from said end plate to expose said cleaning access, said slot opening passing transversely through said end plate opens to said cleaning access, such that an access path for the scraper extends in an upstream direction through said cleaning access, then transversely along said slot opening in said end plate. 
     
     
       23. The deckle system of  claim 14  wherein said retractable base has a first configuration in which said retractable base is locked to said movable carrier and a second configuration in which said retractable base is free to move transversely relative to said movable carrier.